Separable laminated container and associated technology

ABSTRACT

A separable laminated container (A) of the present invention comprises an outer layer ( 1 ) made of synthetic resin and having an air suction hole ( 10 ) and an inner layer ( 2 ) made of synthetic resin and separably laminated on the inside of the outer layer, the inner layer having a portion previously separated from the outer layer just around the air suction hole. The air suction hole can be formed by driving a punch into the outer layer at a neck ( 4 ) of the separable laminated container from the outside, and punching just the outer layer leaving the inner layer behind. The portion of the inner layer previously separated from the outer layer may be left in the inwardly extended state. The inner layer is preferably made of synthetic resin having flextural modules of less than 10,000 kg/cm 2 .

TECHNICAL FIELD

[0001] The present invention relates to a separable laminated container,of which an inner layer is separated from an outer layer and shrinksaccording to the decrease of the liquid content, and the related arts.

BACKGROUND ARTSELATED ART

[0002] A separable laminated container is made up of an outer layer andan inner layer which are made of synthetic resin. The inner layer isseparably laminated to the outer layer. The separable laminatedcontainer is normally used in the sealed state with a pump installed toa neck portion thereof. As the liquid content is poured out by the pump,the inner layer is separated from the outer layer and shrinks accordingto the decrease of the liquid content. In order to smoothly conduct theshrinkage of the inner layer, the outer layer is provided with an airsuction hole.

[0003] As one of methods of forming such an air suction hole, a methodin which the air suction hole is formed by partially fusing the outerlayer of the separable laminated container has been proposed (forexample, Japanese Published Unexamined Patent Application NO.H06-345069). In this method, the inner layer of the laminated containeris made of resin having melting point higher than that of the outerlayer and the resin of the outer layer is only fused to form the airsuction hole by fusion means which is set at a temperature higher thanthe melting point of the outer layer and lower than the melting point ofthe inner layer.

[0004] However, the method of forming the air suction hole as mentionedabove has following problems.

[0005] In case of a little difference between the melting points of theinner layer and the outer layer, it is quite difficult to fuse the outerlayer only. Therefore, a predetermined difference in temperature betweenthe melting points of the inner layer and the outer layer is required,thereby restricting the selection of resins used for the inner layer andthe outer layer.

[0006] Since the air suction hole is formed by fusing the resin of theouter layer by the fusion means, it is difficult to sharply form the airsuction hole into a predetermined configuration. Therefore, a finishingis necessary to make the hole neat.

[0007] Temperature control is necessary to keep the fusion means in aconstant temperature range, thereby complicating the device.

[0008] One of the objects of the present invention is to provide amethod of forming an air suction hole in an outer layer in a desiredconfiguration and the device.

[0009] There is a separable laminated container in which an outer layerand an inner layer are partially bonded as disclosed in JapanesePublished Unexamined Patent Application No. H04-339759, JapanesePublished Unexamined Patent Application No. H05-310265, or the like. Theposition where the outer layer and the inner layer are bonded has beenconsidered variously. For example, the bonded portion is providedlinearly along the longitudinal direction of the separable laminatedcontainer.

[0010] By the way, the separable laminated container is normally made ina method as described below.

[0011] First, a laminated parison or laminated preform (hereinafter,referred to as the laminated parison) having a laminated structurecorresponding to the separable laminated container to be manufactured ismolded by extrusion molding. During this molding, a bonded areaextending the axial direction is provided in a predetermined position insuch a manner as to allow the separation between the outer layer and theinner layer besides the bonded area. Then, the laminated parison is setin the mold and molded into a desired bottle-like configuration by blowmolding in such a manner as to have an air suction hole in the outerlayer.

[0012] For making sure to introduce air through the air suction hole,the position of the air suction hole should be shifted from the bondedarea. When the diameter of the air suction hole is equal to or smallerthan the width of the bonded area, overlap between the air suction holeand the bonded area results the blockage of the air suction hole so thatair can not be introduced into a space the outer layer and the innerlayer and the inner layer can not shrink.

[0013] However, since there is no mark indicating the position of thebonded area in the conventional separable laminated container, the airsuction hole is sometimes formed to be overlapped with the bonded area.

[0014] Another one of the objects of the present invention is to providea separable laminated container allowing an air suction hole to bepositively positioned at a portion shifted from the bonded area.

[0015] By the way, to smoothly separate the inner layer from the outerlayer according to the decrease of the liquid content in the separablelaminated container, pre-separation is made before filling the containerwith the liquid content, for example, as disclosed in Japanese PublishedUnexamined Patent Application No. 06-345069. The conventionalpre-separation is made by blowing air through the air suction hole ofthe separable laminated container to separate the inner layer from theouter layer, then blowing air into the container through the neck, anddeaerating a space between the inner layer and the outer layer throughthe air suction hole so that the inner layer is returned in such amanner as to cling to the inner surface of the outer layer.

[0016] However, in the conventional separable laminated container, theinner layer is made of synthetic resin having a melting point higherthan that of the material of the outer layer and flexural modulesbetween 10,000 kg/cm² and 50,000 kg/cm² (measured by ASTM D790 method ofmeasurement) so as to have good distortion resistance, that is, higherelasticity. Therefore, to smoothly separate the inner layer according tothe decrease of the liquid content, the inner layer must be completelyseparated over the entire laminated area during the pre-separation.

[0017] For that, a predetermined amount of air according to thedimensions of the container should be blown between the layers.Therefore, there is a problem that the separation can not be completedoverall when the control of blowing is mistook.

[0018] Further, a control unit is necessary for controlling the amountof air, thereby complicating the device.

[0019] As well known, since the outer layer and the inner layer shouldbe made of resin having lower bond properties for the purpose ofseparating the inner layer from the outer layer, the inner layer and theouter layer are not completely bonded to each other at a pinch-offportion formed at a bottom of the blow-molded container. This causes acracking of the pinch-off portion and a slit between the layers due to aseparation, thereby causing a sealing defect.

[0020] Under the circumstances mentioned above, the synthetic resinhaving good distortion resistance, that is, higher elasticity asdescribed above further facilitates the defect. There is a problem thatthe container entraps moisture between the inner layer and outer layerfrom the sealing defect when the container is used in a damp area.

[0021] In the conventional pre-separation, the inner layer is separatedfrom the outer layer and then returned in the original position. At thispoint, the inner layer is compressed against the outer layer, therebymaking the separability between the layers low.

[0022] Another one of the objects of the present invention is to providea separable laminated container in which an inner layer can be easilyseparated from an outer layer, and further another one of the objects isto provide a method and device of pre-separation which is easilycompleted by partly separating the inner layer with a small amount ofair.

[0023] Since, once separated from the outer layer, the inner layer isreturned in such a manner as to cling to the inner surface of the outerlayer in the conventional pre-separation, the level to which thepre-separation is finished does not appear externally so that it isdifficult to inspect the level.

[0024] Another one of the objects of the present invention is to providea separable laminated container which allowing the easy inspection ofthe level to which the pre-separation is finished.

[0025] In case of a container for liquid, since the ratio of the amountof liquid content to the capacity of the container is generallyconstant, larger capacity of the container makes an upper space afterfilled with the liquid content larger so that the level is sometimeslowered to a lower portion of a shoulder or near an upper end of thedrum portion of the container.

[0026] In case of installing a pump to the neck of the container, takinginto consideration the rise of the level due to the insertion of thepump and troubles for inserting the pump, the liquid content is filledin the container in such a manner as to have larger upper space, therebysometimes lowering the level.

[0027] As the upper space is increased and the level of the liquid islowered to the lower portion of the shoulder or near the upper end ofthe drum of the container as mentioned above, the water face of theliquid content waves and the splash of the liquid content becomesviolent, thereby bubbling the liquid content and/or generating gasesdepending on the kind of the liquid content.

[0028] As the level of the liquid content is lowered to the upper end ofthe drum of the container, in case of transparent or translucentcontainer, this gives consumers the impression that the content is lessthan the indicated amount of content even when the container is filledwith the content of amount equal to the indicated amount. Even in caseof opaque container, it also gives consumers the same impression becauseof the degree of the splash of the liquid content when swinging thecontainer.

[0029] Another one of the objects of the present invention is to providea pre-separation method allowing smaller upper space when a container isin the filled state, and a container with a pump allowing smaller upperspace.

DISCLOSURE OF INVENTION

[0030] The first feature of the present invention is included in aseparable laminated container comprising: (a) an outer layer made ofsynthetic resin and having an air suction hole; and (b) an inner layermade of synthetic resin, and separably laminated on the inside of theouter layer, the inner layer having a portion previously separated fromthe outer layer just around th air suction hole.

[0031] In the separable laminated container with the first feature, airis smoothly introduced between the outer layer and the inner layer evenat the first time to pour out the liquid content for use so that theseparation of the inner layer is easily made. Since only a part of theinner layer is separated in the pre-separation, a small amount of airfor the pre-separation is enough.

[0032] In the separable laminated container with the first feature ofthe present invention, the position of the air suction hole is notlimited so that the air suction hole may be formed in any place.Therefore, the air suction hole may be formed in a neck of the containeror a drum portion of the container. In addition, the method for formingthe air suction hole is also not limited so that a welding means or apunching means by a punch may be employed.

[0033] In the separable laminated container with the first feature ofthe present invention, though the resin materials for the inner layerand the outer layer are not limited, it is preferable that resins whichallow the easy separation therebetween are employed. As for the innerlayer, a resin with high flexibility is preferably employed.

[0034] The separable laminated container with the first feature of thepresent invention may further comprise a neck, wherein the neck isprovided with the air suction hole formed in the outer layer by drivinga punch from the outside of the outer layer and punching the outerlayer, leaving the inner layer behind.

[0035] The separable laminated container with the first feature of thepresent invention may further comprise a neck, wherein the neck isprovided with the air suction hole formed in the outer layer, andwherein the inner layer has an extended portion extended toward theinward of the neck at the part previously separated from the outer layernear the neck. As structured above, the extended portion of the innerlayer can be observed from an upper position over the neck of thecontainer, thereby facilitating the check of the state of thepre-separation and thus making the inspection. For pouring out theliquid content, air is securely entered from the first time to pour outthe liquid content so as to proceed the separation, thereby improvingthe entire separability. In case of filling a fixed volume of the liquidcontent into the container, since the upper space after filling isreduced by the volume excluded by the extended portion, the level of theliquid content can be risen to a desired level by controlling the volumeof the air for pre-separation. Particularly, when the level is risen tothe neck of the container, it can decrease the waves of the water faceof the liquid content during the container A is transported. Even whenthe liquid content generates gases, the inner layer is moved by thepressure of the gases so that the profile of the container is notchanged.

[0036] The second feature of the present invention is included in aseparable laminated container comprising: (a) an outer layer made ofsynthetic resin and having an air suction hole; and (b) an inner layermade of synthetic resin having flexural modules of less than 10,000kg/cm² and separably laminated on the inside of the outer layer.

[0037] In the separable laminated container with the second feature, thesynthetic resin having flexural modules of less than 10,000 kg/cm² isemployed as the material of the inner layer so that the inner layerseparated form the outer layer shrinks according to the decrease of thecontent in the separable laminated container in use.

[0038] In the separable laminated container with the second feature ofthe present invention, the position of the air suction hole is notlimited so that the air suction hole may be formed in any place.Therefore, the air suction hole may be formed in a neck of the containeror a drum portion of the container. In addition, the method for formingthe air suction hole is also not limited so that a welding means or apunching means by a punch may be employed.

[0039] In the separable laminated container with the second feature ofthe present invention, though the resin materials for the inner layerand the outer layer are not limited but making the inner layer havingflexural modules of less than 10,000 kg/cm², it is preferable thatresins which allow the easy separation therebetween are employed.

[0040] The separable laminated container with the second feature of thepresent invention may further comprise a neck, wherein the neck isprovided with the air suction hole formed in the outer layer.

[0041] In the separable laminated container with the second feature ofthe present invention, a portion of the inner layer adjacent to the airsuction hole may be previously partly separated from the outer layer. Asstructured above, air is smoothly introduced between the outer layer andthe inner layer even at the first time to pour out the liquid contentfor use so that the separation of the inner layer is easily made and theshrinkage and deformation of the inner layer is easily conducted. Sinceonly a part of the inner layer is separated in the pre-separation, asmall amount of air for the pre-separation is enough. In this case also,the position of the neck is not limited and the method of forming a holeis not limited.

[0042] The separable laminated container with the second feature of thepresent invention may further comprise a neck, wherein the neck isprovided with the air suction hole formed in the outer layer, andwherein a portion of the inner layer adjacent to the air suction hole ispartly separated from the outer layer.

[0043] The third feature of the present invention is included in aseparable laminated container comprising: (a) an outer layer made ofsynthetic resin, having an air suction hole, and provided with a markcomposed of projections or indents which are formed in the outer surfacethereof during molding into a container configuration; and (b) an innerlayer made of synthetic resin, separably laminated on the inside of theouter layer, and partly bonded with the outer layer by a bonded layer,the bonded layer disposed apart from the air suction hole.

[0044] In the separable laminated container with the third feature, themark is formed during molding into a container configuration so that thepositional relation between the bonded area and the mark is defined.Therefore, the mark formed in the outer surface of the outer layerpermits the secure recognition of the circumferential direction or theaxial direction and the position of the bonded area so that the bondedarea and the air suction hole can be securely shifted from each otherwhen the position of the air suction hole is set based on the positionof the mark.

[0045] In the separable laminated container with the third feature ofthe present invention, the position of the air suction hole is notlimited so that the air suction hole may be formed in any place.Therefore, the air suction hole may be formed in a neck of the containeror a drum portion of the container. In addition, the method for formingthe air suction hole is also not limited so that a welding means or apunching means by a punch may be employed.

[0046] In the separable laminated container with, the third feature ofthe present invention, though the resin materials for the inner layerand the outer layer are not limited, it is preferable that resins whichallow the easy separation therebetween are employed. As for the innerlayer, a resin with high flexibility is preferably employed. The crosssection of the separable laminated container is not limited particularlyand thus may be any one of various configurations such as circle,ellipse, and rectangle.

[0047] In the separable laminated container with the third feature ofthe present invention, the bonded area may be linearly formed along theaxial direction of the separable laminated container, may becircumferentially formed in a ring-like configuration, or may be partlyformed in some spots. In addition, the mark may be formed in a positioncorresponding to the bonded area or in a position shifted from thebonded area.

[0048] In the separable laminated container with the third feature ofthe present invention, the bonded layer extends in the longitudinaldirection of the container.

[0049] The fourth feature of the present invention is included in acontainer with pump comprising: (a) a container body made up of an innerlayer and an outer layer which are made of synthetic resin and separablylaminated on each other, wherein the outer layer has an air suction holeformed therein and a portion of the inner layer adjacent to the airsuction hole is partly separated from the outer layer; and (b) a pumpcomprising a cylinder inserted into the container body through a neck ofthe container body and a cap whereby the pump is hermetically fitted tothe neck, wherein the cylinder is provided with a flange-like sealaround the outer periphery thereof, the flange-like seal coming incontact with the inner surface of the neck tightly.

[0050] In the container with pump with the fourth feature, air issmoothly introduced between the outer layer and the inner layer even atthe first time to pour out the liquid content for use so that theseparation of the inner layer is easily made. Since only a part of theinner layer is separated in the pre-separation, a small amount of airfor the pre-separation is enough.

[0051] In the container with pump with the fourth feature of the presentinvention, the inner layer is inwardly extended in the pre-separation ofthe container. When the cylinder of the pump is inserted through theneck of the container body after filling the liquid content into thecontainer body, the cylinder is inserted with the flange-like sealsealing the neck so that the inner pressure of the container body isrisen so as to return th extended portion of the inner layer into theoriginal state, thereby discharging the air, which has been blownbetween the inner layer and the outer layer, through the air suctionhole. The extended portion of the inner layer may be brought in contactwith the outer layer by completely discharging the air, which has beenblown between the inner layer and the outer layer in the pre-separation.Alternatively, some of the air may be left between the inner layer andthe outer layer even after the installation of the pump so that theinner layer and the outer layer is spaced from each other.

[0052] In the container with pump with the fourth feature of the presentinvention, the position of the air suction hole is not limited so thatthe air suction hole may be formed in any place. Therefore, the airsuction hole may be formed in a neck of the container or a drum portionof the container. In addition, the method for forming the air suctionhole is also not limited so that a welding means or a punching means bya punch may be employed.

[0053] In the container with pump with the fourth feature of the presentinvention, though the resin materials for the inner layer and the outerlayer are not limited, it is preferable that resins which allow the easyseparation therebetween are employed. As for the inner layer, a resinwith high flexibility is preferably employed.

[0054] The fifth feature of the present invention is included in acontainer with pump comprising: (a) a container body made up of an innerlayer and an outer layer which are made of synthetic resin and separablylaminated on each other, wherein the outer layer has an air suction holeformed therein and a portion of the inner layer adjacent to the airsuction hole is partly separated from the outer layer; (b) a pumpcomprising a cylinder inserted into the container body through a neck ofthe container body and a cap whereby the pump is hermetically fitted tothe neck; and (c) an inner lid having a ring-like seal coming in contactwith the outer surface of the cylinder of the pump tightly, and fittedin the neck of the container body.

[0055] In the container with pump with the fifth feature, air issmoothly introduced between the outer layer and the inner layer even atthe first time to pour out the liquid content for use so that theseparation of the inner layer is easily made. Since only a part of theinner layer is separated in the pre-separation, a small amount of airfor the pre-separation is enough.

[0056] In the container with pump with the fifth feature of the presentinvention, the inner layer is inwardly extended in the pre-separation ofthe container. When the cylinder of the pump is inserted through theneck of the container body after filling the liquid content into thcontainer body and fitting the inner lid into the neck of the containerbody, the cylinder of the pump is inserted with the cylinder sealing thering-like seal so that the inner pressure of the container body is risenso as to return the previously extended portion of the inner layer intothe original state, thereby discharging the air, which has been blownbetween the inner layer and the outer layer, through the air suctionhole. The extended portion of the inner layer may be brought in contactwith the outer layer by completely discharging the air, which has beenblown between the inner layer and the outer layer in the pre-separation.Alternatively, some of the air may be left between the inner layer andthe outer layer even after the installation of the pump so that theinner layer and the outer layer is spaced from each other.

[0057] In the container with pump with the fifth feature of the presentinvention, the position of the air suction hole is not limited so thatthe air suction hole may be formed in any place. Therefore, the airsuction hole may be formed in a neck of the container or a drum portionof the container. In addition, the method for forming the air suctionhole is also not limited so that a welding means or a punching means bya punch may be employed.

[0058] In the container with pump with the fifth feature of the presentinvention, though the resin materials for the inner layer and the outerlayer are not limited, it is preferable that resins which allow the easyseparation therebetween are employed. As for the inner layer, a resinwith high flexibility is preferably employed.

[0059] In the container with pump with the fifth feature of the presentinvention, the cylinder may have narrow grooves or a roughened surfaceon the outer surface thereof extending from the lower edge thereof to aposition above the seal of the inner lid after installation of the pump.

[0060] In the container with pump with the fifth feature of the presentinvention, the seal of the inner lid may have a narrow groove or aroughened surface formed in a sealing surface thereof.

[0061] In the container with pump with the fifth feature of the presentinvention, the seal of the inner lid may protrude inward and upward insuch a manner as to elastically expand and contract in the radialdirection.

[0062] The sixth feature of the present invention is included in apunching method of an air suction hole in a separable laminatedcontainer comprising steps of: driving a punch from the outside into aneck of a container body made up of an inner layer and an outer layerwhich are made of synthetic resin and separably laminated on each other;and punching out the outer layer by the blade of the punch, leaving theinner layer behind.

[0063] In the punching method with the sixth feature, the outer layer ispunched by the blade of the punch leaving the inner layer behind so thatthe air suction hole can be formed only in the outer layer whereby theair suction hole can be quite easily formed. The air suction hole can beformed in the same configuration as that of the blade and the hole isneatly made only by the punching so that no finishing after the punchingis required. Particularly when this punching method is conducted duringthe molded container is in a predetermined range of temperature afterblow molding, it further facilitates and secures the formation of theair suction hole.

[0064] The seventh feature of the present invention is included in apunching device comprising: (a) a pedestal which is inserted into a neckof a container body made up of an inner layer and an outer layer, whichare made of synthetic resin and separably laminated on each other, tocome in contact with an inner surface of the neck; (b) a punch supportedin such a manner as to come close to and move away from the pedestal,the punch having a tubulous blade; and (c) a space keeping mechanism forkeeping a distance between the tubulous blade and the pedestal constantwhen the punch is at the nearest position to the pedestal.

[0065] The punching device with the seventh feature is suitable forcarrying out the invention of the punching method with the sixthfeature.

[0066] The punching device with the seventh feature of the presentinvention has a simple structure and facilitates the formation of theair suction hole. Since the punch pushes the inner layer at the sametime of punching out the outer layer, the separation between the layersare made around the air suction hole during punching, thereby allowingthe inner layer to be quite easily separated from the outer layer.

[0067] The punching device with the seventh feature further comprises anadjusting mechanism for adjusting the distance between the tubulousblade and the pedestal at a point in time when the punch is at thenearest position to the pedestal. As structured above, the adjustingmechanism adjusts the distance between the tubulous blade and thepedestal so that the air suction hole can be formed only in the outerlayer even with a spread in the thickness of the inner layer.

[0068] The eighth feature of the present invention is included in apre-separation method for a separable laminated container comprisingsteps of: punching an air suction hole in an outer layer of a separablelaminated container made up of an inner layer and the outer layer whichare made of synthetic-resin and separably laminated on each other; andintroducing a little amount of air through the air suction hole topreviously separate a portion of the inner layer around the air suctionhole from the outer layer.

[0069] In the pre-separation method with the eighth feature, since onlya part of the inner layer is separated, a small amount of air for thepre-separation is enough and it is not necessary to change the volume ofthe air even with containers of somewhat different volumes, therebyallowing easy operation. The extended portion of the inner layer may bebrought in contact with the outer layer again or may be left in thestate separated from the outer layer.

[0070] In the pre-separation method with the eighth feature, the methodof forming the air suction hole is not limited so that the hole mayformed by welding the outer layer or punching only the outer layer by apunch.

[0071] In the pre-separation method with the eighth feature, the innerlayer of the separable laminated layer is preferably made of syntheticresin having flexural modules of less than 10,000 kg/cm². Thisfacilitates the separation of the inner layer and allows smoothshrinkage and deformation of the inner layer during using the separablelaminated container.

[0072] The ninth feature of the present invention is included in apre-separation method for a separable laminated container comprisingsteps of: punching an air suction hole in an outer layer of a separablelaminated container made up of an inner layer and the outer layer whichare made of synthetic resin and separably laminated on each other;introducing a little amount of air through the air suction hole topreviously separate a portion of the inner layer around the air suctionhole from the outer layer; blowing air into the inside of the separablelaminated container to discharge the air introduced between the innerlayer and the outer layer; and bringing the separated layer in contactwith the outer layer again.

[0073] In the pre-separation method with the ninth feature, since only apart of the inner layer is separated, a small amount of air for thepre-separation is enough and it is not necessary to change the volume ofthe air even with containers of somewhat different volumes, therebyallowing easy operation. Though the inner layer separated from the outerlayer is brought in contact with the outer layer again, the separatedinner layer can be easily separated from the outer layer again.

[0074] In the pre-separation method with the ninth feature, the methodof forming the air suction hole is not limited so that the hole mayformed by welding the outer layer or punching only the outer layer by apunch.

[0075] In the pre-separation method with the ninth feature, the innerlayer of the separable laminated layer is preferably made of syntheticresin having flexural modules of less than 10,000 kg/cm². Thisfacilitates the separation of the inner layer and allows smoothshrinkage and deformation of the inner layer during using the separablelaminated container.

[0076] The tenth feature of the present invention is included in apre-separation method for a separable laminated container comprisingsteps of: punching an air suction hole in an outer layer of a separablelaminated container made up of an inner layer and the outer layer whichare made of synthetic resin and separably laminated on each other;introducing a little amount of air through the air suction hole topreviously separate a portion of the inner layer around the air suctionhole from the outer layer; installing a pump to a neck of the separablelaminated container after filling liquid content in the separablelaminated container; sealing a space between the cylinder of the pumpand the neck by a seal when a cylinder of the pump is inserted into theneck during the installation so as to discharge at least some of the airintroduced between the inner layer and the outer layer.

[0077] In the pre-separation method with the tenth feature, at leastsome of the air previously introduced between the inner layer and theouter layer is enough to be discharged through the air suction hole.This means that the inner layer may be returned to come in contact withthe inner surface of the outer layer by completely discharging theintroduced air during the installation of the pump, or, some of the airmay be left between the inner layer and the outer layer even after theinstallation of the pump so that the inner layer and the outer layer isspaced from each other.

[0078] In the pre-separation method with the tenth feature, since only apart of the inner layer is separated, a small amount of air for thepre-separation is enough. The step of completely or partly returning theinner layer to the original state and the step of installing the pump tothe separable laminated container can be conducted by one action,thereby facilitating the manufacturing process of the container withpump.

[0079] In the pre-separation method with the tenth feature, the methodof forming the air suction hole is not limited so that the hole mayformed by welding the outer layer or punching only the outer layer by apunch.

[0080] In the pre-separation method with the tenth feature, the amountof residual air in the inner layer after installation of the pump may becontrolled by controlling the amount of air introduced through the airsuction hole to partly separate the inner layer from the outer layer.

[0081] In the pre-separation method with the tenth feature, the seal isformed on the circumference of the cylinder of the pump and the amountof air discharged through the air suction hole during the installationof the pump can be controlled by the sliding range of the seal againstthe neck and the position of the air suction hole.

[0082] In the pre-separation method with the tenth feature, the sealcomprises an inner lid fitted in the neck in such a manner as to allowthe insertion of the cylinder of the pump therethrough and the amount ofair discharged through the air suction hole during the installation ofthe pump can be controlled by the length of the cylinder inserted intothe seal.

[0083] In the pre-separation method with the tenth feature, theseparated inner layer can be brought in contact with the outer layeragain by adjusting the amount of air introduced through the air suctionhole to the same amount of the air discharged through the air suctionhole during the installation of the pump.

[0084] The eleventh of the present invention is included in apre-separation device for a separable laminated container comprising;(a) a first air supply member for supplying air between an inner layerand an outer layer of a separable laminated container, which are made ofsynthetic resin and separably laminated on each other, through an airsuction hole punched in the outer layer of the separable laminatedcontainer; (b) a second air supply member for blowing air into theseparable laminated container through a neck of the separable laminatedcontainer; (c) a pressurized air supply device for supplying pressurizedair into the first air supply member and the second air supply member;(d) a pressurized air storage disposed between the first air supplymember and the pressurized air supply device; (e) solenoid valvesdisposed between the pressurized air supply device and the pressurizedair storage, between the first air supply member and the pressurized airstorage, and between the second air supply member and the pressurizedair supply device, respectively; and (f) a control means for activatingthe solenoid valves at predetermined timings.

[0085] The pre-separation device with the eleventh feature is suitablefor carrying out the invention of the punching method with the ninthfeature. A little volume of the pressurized air of the pressurized airsupply device is first stored in the pressurized air storage, then thepressurized air stored in the pressurized air storage is introducedbetween the inner layer and the outer layer of the separable laminatedcontainer through the air suction hole by the first air supply member soas to separate the inner layer around the air suction hole from theouter layer, and after that, the separated inner layer is brought incontact with the inner surface of the outer layer by blowing thepressurized air into the separable laminated container by the second airsupply member. A sequence of actions as mentioned above are securely andeasily carried out by controlling the solenoid valves by the controlmeans.

[0086] The pre-separation device with the eleventh feature of th presentinvention may further comprise an adjusting means for adjusting theamount of the pressurized air stored in the pressurized air storage. Asthe adjusting means are provided as mentioned above, the volume of theair for separating the inner layer can be changed if necessary.

[0087] In the pre-separation device with the eleventh feature of thepresent invention, the first air supply member may comprise a nozzleinserted into the air suction hole of the separable laminated container,wherein the nozzle is opened at the front end and a side thereof so thatthe air supplied between the inner layer and the outer layer isdischarged through the nozzle when air is blown into the separablelaminated container through the second air supply member. As structuredabove, the air introduced between the inner layer and the outer layercan be completely discharged with the second air supply member ismounted on the separable laminated container, with the result that theentire surface of the separated inner layer can be brought in contactwith the inner surface of the outer layer as the original state.

BRIEF DESCRIPTION OF DRAWINGS

[0088]FIG. 1 is a front view showing a separable laminated containeraccording to a first embodiment of the present invention;

[0089]FIG. 2 is a front view showing a punching device of the firstembodiment of the present invention, parts being broken away;

[0090]FIG. 3 is a perspective view of a separable laminated containeraccording to a second embodiment of the present invention;

[0091]FIG. 4 is a plan view of the separable laminated containeraccording to the second embodiment of the present invention;

[0092]FIG. 5 is a cross sectional view showing the separable laminatedcontainer according to the second embodiment of the present inventionbefore separation of an inner layer;

[0093]FIG. 6 is a front view of a separable laminated containeraccording to a third embodiment of the present invention, parts beingbroken away;

[0094]FIG. 7 is a longitudinal sectional view of the separable laminatedcontainer according to the third embodiment of the present invention, asshown from the right side;

[0095]FIG. 8 is a longitudinal sectional view of a pre-separation deviceaccording to the third embodiment of the present invention;

[0096]FIG. 9 is an enlarged longitudinal sectional view showingcomponents of the pre-separation device in the third embodiment of thepresent invention;

[0097]FIG. 10 is a left side view of a first air supply member of thepre-separation device in the third embodiment of the present invention;

[0098]FIG. 11 is a front view showing the first air supply member of thepre-separation device in the third embodiment of the present invention,parts being broken away;

[0099]FIG. 12 is a pneumatic piping drawing of the pre-separation devicein the third embodiment of the present invention;

[0100]FIG. 13 is a longitudinal sectional view of a volume controller ofthe pre-separation device in the third embodiment of the presentinvention;

[0101]FIG. 14 is a timing chart of the pre-separation device in thethird embodiment of the present invention;

[0102]FIG. 15 is a front view of showing a separable laminated containeraccording to a fourth embodiment of the present invention, parts beingbroken away;

[0103]FIG. 16 is a plan view of the separable laminated containeraccording to the fourth embodiment of the present invention;

[0104]FIG. 17 is a right side view of the separable laminated containeraccording to the fourth embodiment of the present invention;

[0105]FIG. 18 is a front view showing the separable laminated containeraccording to the fourth embodiment of the present invention duringpre-separation, parts being broken away;

[0106]FIG. 19 is a longitudinal sectional view of a pre-separationdevice in the fourth embodiment of the present invention;

[0107]FIG. 20 is a front view showing a container with pump according toa fifth embodiment of the present invention, parts being broken away;

[0108]FIG. 21 is a front view showing a container body of the containerwith pump in the fifth embodiment of the present invention parts beingbroken away;

[0109]FIG. 22 is a longitudinal sectional view of a pre-separationdevice in the fifth embodiment of the present invention;

[0110]FIG. 23 is a front view showing the container body of thecontainer with pump during the pre-separation in the fifth embodiment ofthe present invention, parts being broken away;

[0111]FIG. 24 is a right side view showing the container body of thecontainer with pump during the pre-separation in the fifth embodiment ofthe present invention;

[0112]FIG. 25 is a sectional view showing components in the containerwith pump in an initial stage of installing a pump according to thefifth embodiment of the present invention;

[0113]FIG. 26 is a sectional view showing components in the containerwith pump when the installation of the pump is completed according tothe fifth embodiment of the present invention;

[0114]FIG. 27 is a sectional view showing components in a container withpump in an initial stage of installing a pump according to a sixthembodiment of the present invention;

[0115]FIG. 28 is a sectional view showing components in the containerwith pump when the installation of the pump is completed according tothe sixth embodiment of the present invention;

[0116]FIG. 29 is a half-sectional view of an inner lid of the containerwith pump according to the sixth embodiment of the present invention;

[0117]FIG. 30 is a front view of a pump of a container with pumpaccording to a seventh embodiment of the present invention;

[0118]FIG. 31 is a sectional view showing the container with pump whenthe installation of the pump is completed according to the seventhembodiment of the present invention;

[0119]FIG. 32 is a front view of a conventional container with pump;

[0120]FIG. 33 is a half-sectional view of an inner lid of a containerwith pump according to an eighth embodiment of the present invention;

[0121]FIG. 34 is a sectional view showing components of a container withpump in an initial stage of installing a pump according to a ninthembodiment of the present invention;

[0122]FIG. 35 is a sectional view showing components of the containerwith pump when the installation of the pump is completed according tothe ninth embodiment of the present invention;

[0123]FIG. 36 is a half-sectional view of an inner lid of the containerwith pump according to the ninth embodiment of the present invention;and

[0124]FIG. 37 is an enlarged sectional view of components of thecontainer with pump according to the ninth embodiment of the presentinvention, showing the state filled with liquid content.

BEST MODE FOR CARRYING OUT THE INVENTION

[0125] Hereinafter, embodiments of the present invention will bedescribed with reference to attached drawings.

[0126] [First Embodiment]

[0127]FIG. 1 is a front view of a separable laminated containerA-according to a first embodiment. The separable laminated container Ais made up of an outer layer 1 and an inner layer 2, is formed by blowmolding, and comprises a drum portion 3, a neck 4, and a bottom 5.

[0128] The outer layer 1 is made of high-density polyethylene to keepthe profile of the container, and the inn r layer 2 is an inner bag madeof nylon which is separable from the outer layer and deformable. Thereis a separated area 8 formed between the outer layer 1 and the innerlayer 2 and a bonded area 9 where the outer layer 1 and the inner layer2 are partly bonded in the longitudinal direction.

[0129] The bottom 5 of the container A is provided with a projection 6which is formed by pinch-offs of a mold during the molding. Theprojection 6 is provided with a plurality of sunk portions 7 which arearranged zigzag and each sunk in the opposite bonded layer.

[0130] The projection 6 allows the inner layer 2 strongly bonded to theouter layer 1 even when the inner layer 2 is made of resin such as nylonproviding weak bond strength, thereby preventing the occurrence of slitdue to the separation between the layers and thus preventing theentrapment of moisture.

[0131] The neck 4 is provided with an engaging portion 10 formed at anupper end of inner layer 2 by an air blowing member during the blowmolding.

[0132] The neck 4 is also provided with an air suction hole 11 formed bya punching device in a punching method of the present invention. The airsuction hole 11 is a hole for introducing air into a space between theinner layer 2 and the outer layer 1 in order to smoothly achieve theseparation of the inner layer 2 with keeping the profile of thecontainer A to completely pour out th content.

[0133] Hereinafter, the description will be made as regard to a methodof punching the air suction hole and the punching device of the presentinvention, with reference to FIG. 2.

[0134] The punching device B is disposed during cooling stage of theblow-molded container A and mounted on a supporting bed (not shown)capable of moving vertically and laterally.

[0135] The punching device B comprises a receiving member B₁ and acutting member B₂ which are mounted on a supporting member 20.

[0136] The supporting member 20 is mounted on the supporting bed (notshown) and comprises a supporting shaft 21 and a guiding pole 22,wherein the guiding pole 22 is arranged in parallel with the supportingshaft 21 and is provided with a stopper 23 at the end thereof.

[0137] The receiving member B₁ comprises a supporting pole 24, which isfixed to the supporting shaft 21 and extends downward, and a pedestal 25disposed at an end of the supporting pole 24.

[0138] The cutting member B₂ comprises a sliding member 30, which is notallowed to rotate relative to the supporting shaft 21 and the guidingpole 22 and is allowed to slide laterally, a supporting pole 31extending downward from the sliding member 30, and a punch 32 disposedat the end of the supporting pole 31 in such a manner as to face thepedestal 25.

[0139] The punch 32 is provided with a tubulous blade 33 at the endthereof and a clearance hole 34 formed therein for discharging a chip.

[0140] The supporting pole 31 is provided with an internal thread 35formed at the proximal end side thereof, into which a bolt 36 as astopper is screwed and fixed by a lock nut 37 not to shift from a fixedposition.

[0141] Where the distal end 38 of the bolt 36 comes into contact withthe supporting pole 24 of the receiving member B₁, there is a distance tbetween the tubulous blade 33 and the receiving face 26 of the pedestal25. The size of the distance t is adjustable by adjusting the positionof the bolt 36 relative to the internal thread 35. It should be notedthat the bolt 36 and the supporting pole 24 constitute a space keepingmechanism and the internal thread 35, the bolt 36, and the lock nut 37constitute an adjusting mechanism.

[0142] The supporting bed is provided with driving means (not shown) formoving the sliding member 30 laterally in such a manner that the slidingmember 30 reciprocates between a waiting position where the slidingmember 30 comes into contact with the stopper 23 disposed at the end ofthe guiding pole 22 and a punching position where the distal end 38 ofthe bolt 36 comes into contact with the supporting pole 24 of thereceiving member.

[0143] A combination of an electric or mechanical driving source, whichis controlled in connection with the stopping member, and suitabletransmitting means can be selected as the driving means, or manual meansmay also be employed as the driving means.

[0144] Though the waiting position and the punching position of thesliding member 30 are defined by the stopping member in this embodiment,these may be defined by controlling the operational range of the drivingmeans instead of the stopping member.

[0145] The description will now be made as regard to the operation ofthe punching device B and the punching method of the present invention.

[0146] As mentioned above, the punching device B is disposed during thecooling stage and the punching is performed during the container A has apredetermined temperature before returning to the room temperature.

[0147] During the punching device B is in non-operation, the supportingbed is positioned above the container A in such a manner as to move thecontainer A. Therefore, the receiving member B₁ and the cutting memberB₂ are also positioned above the container A as well as the supportingmember 20.

[0148] The sliding member 30 is positioned at the waiting position at apredetermined distance from the supporting member 20.

[0149] As the container A prior to punching is moved to a predeterminedposition, the supporting bed relatively moves downward against thecontainer A, the supporting pole 24 mounted on the supporting member 20is inserted into the neck 4 of the container A, and the pedestal 25 isdisposed at a position being in contact with the inner layer 2.

[0150] At the same time, the cutting member B2 mounted on the slidingmember 30 moves downward as well as the supporting member 20 in such amanner that the pedestal 25 and the tubulous blade 33 of the punch 32face each other to put the inner layer 2 and the outer layer 1 of theneck 4 of the container A therebetween.

[0151] Then, the sliding member 30 is moved in the direction of X by thedriving means so that the punch 32 moves until the distal end 38 of thebolt 36 comes into contact with the supporting pole 24.

[0152] At this point, the punch 32 presses the inner layer 2 of the neck4 of the container A to the receiving face 26 of the pedestal 25 andthen the tubulous blade 33 is pressed to enter into the outer layer 1 ofthe neck 4 of the container A so as to punch the outer layer 1, leavingthe inner layer 2 behind, thereby punching the air suction hole 11 inthe outer layer 1.

[0153] Since the punching is performed during the container A has thepredetermined temperature after the container A is formed by blowmolding, the outer layer is easily punched by the punch 32.

[0154] After the punching, the sliding member 30 moves in the directionof Y to return to the waiting position and the supporting member 20moves upward for the next punching.

[0155] As the distance t between the tubulous blade 33 at the end of thepunch 32 and the receiving face 26 is adjusted to the thickness of theinner layer 2, the air suction hole can be formed only in the outerlayer 1.

[0156] Though there is a spread in the thickness of the inner layer 2formed by blow molding, the distance t is set to the minimum thicknessof the inner layer 2, thereby punching the air suction hole 11 only inthe outer layer 1 even with the spread in the thickness.

[0157] In the next stage after the punching, for a pre-separationbetween the outer layer 1 and the inner layer 2, air is blown throughthe air suction hole 11 thus punched to introduce the air into a spacebetween the inner layer 2 and the outer layer 1.

[0158] Since the layers have been separated at the periphery of the airsuction hole 11 during the punching, the separation throughout thelayers can be easily made only by introducing a small amount of air.

[0159] According to the punching method and the punching device of thepresent invention, the air suction hole 11 can be quite easily formed inthe outer layer 1 of the neck 4 of the container A. Further, the airsuction hole can be formed in a predetermined configuration by thetubulous blade, that is, the hole is neatly made only by the punching sothat no finishing after the punching is required. In addition, thepunching device can be easily structured.

[0160] [Second Embodiment]

[0161]FIG. 3 is a perspective view of a separable laminated container Aaccording to a second embodiment, FIG. 4 is a plan view of the same, andthe FIG. 5 is a cross-sectional view of a drum portion thereof.

[0162] The container A comprises a drum portion 102 having an ellipticalsection, a shoulder 103 continuously connected to the upper part of thedrum portion 102, and a cylindrical neck 104 extending upward from thecenter of the shoulder 103. The container A is made up of an outer layer111 and an inner layer 112 overall from the neck 104 to a bottom 105 ofthe drum portion 102. The outer layer 111 and the inner layer 112 arebonded each other at a strip of bonded area 113, while the outer layer111 and the inner layer 112 are just in contact with each other besidesthe bonded area 113 in such a manner as to be separable from each other.FIG. 5 shows a state before the inner layer 112 is separated from theouter layer 111.

[0163] The bonded area 113 linearly extends from the top of the neck 104to the lower edge of the drum portion 102 in the longitudinal directionof the container A and extends to the center of the bottom 105.

[0164] The neck 104 of the container A is provided with an air suctionhole 114 formed in the outer layer 111, 180* apart from the bonded area113 in the peripheral direction. The air suction hole 114 is piercedonly in the outer layer 111, not in the inner layer 112.

[0165] The shoulder 103 is provided with three projections 115 formed ina line, as marks for peripheral positioning, in position 90° apart formthe bonded area and the air suction hole 114 in the peripheraldirection. In other words, the bonded area 113 is positioned at theright side of and 90° apart from the projections 115 in the peripheraldirection and the air suction hole 114 is positioned at the left side ofand 90° apart from the projections 115 in the peripheral direction.

[0166] In the container A, a pump not shown is mounted in the neck 104with the suction tube inserted into the container A through the neck 104so that the content filled inside the inner layer 112 is pumped up andpoured out through the pump.

[0167] According to the decrease of the content within the inner layer112, the inner layer 112 is separated from the outer layer 111 andshrinks. Where in the inner layer 112 the separation and shrinkage arestarted is dependent on the thickness distribution of the inner layer112 or the like. Usually, the separation and shrinkage are started froma distant portion from the bonded area 113. When the pre-separationbetween the out r layer 111 and the inner layer 112 was made beforefilling the content, the separation and the shrinkage are started fromthe pre-separated portion.

[0168] During the shrinkage of the inner layer 112, air is introducedbetween the outer layer 111 and the inner layer 112 through the airsuction hole 114, thereby making the shrinkage of the inner layer 112secure and smooth.

[0169] The container A is made as follows.

[0170] First, a laminated parison or laminated preform (hereinafter,referred to as the laminated parison) having a laminated structurecorresponding to the separable laminated container to be manufactured ismolded by extrusion molding or the like. During this molding, a bondedarea extending the axial direction is provided in a predeterminedposition along the whole length thereof in such a manner as to allow theseparation between the outer layer and the inner layer besides thebonded area.

[0171] Then, the laminated parison is set in the mold and molded into adesired bottle-like configuration by blow molding in such a manner as tohave an air suction hole in the outer layer. The blow mold is providedwith three little concavities in a molding face of the shoulder 3, whichis elliptical as seen from the top, of the container at the minor axisside thereof. These concavities are to form the projections 115 as marksfor peripheral positioning. The projections 115 are formed by pushingparts of the outer layer into the concavities.

[0172] The laminated parison is set in the mold in such a manner thatthe bonded area of the laminated parison is positioned at the major axisside of the molding face of the elliptical shoulder 103. Therefore, theprojections 115 can be made at the position 90° apart form the bondedarea 113 in the peripheral direction.

[0173] As mentioned above, since the projections 115 are formed duringthe molding into the bottle-like configuration, the positional relationbetween the bonded area 113 and the projections 115 is defined.

[0174] After the blow molding into the desired container configurationas mentioned above, the air suction hole 114 is punched in the outerlayer 111 of the neck 104 by using the punching device of theaforementioned first embodiment. During the punching, the air suctionhole 114 is punched at a position 90* apart from the projections 115 inthe peripheral direction on the left of the projections 115 as seen withthe projections 115 positioned on this side so that the air suction hole114 can be positioned at the opposite side of (180* apart from) thebonded area 113, thereby securely preventing the overlapping of thebonded area 113 and the air suction hole 114.

[0175] That is, since the position of the projections 115 of theshoulder 103 is defined, the position of the bonded area 113 is alsodefined. As the punched position of the air suction hole 114 is definedon the basis of the projections 115, the bonded area 113 and the airsuction hole 114 can be securely formed apart from each other.

[0176] When a sensor such as an optical sensor is used for detecting theprojections 115, the container A can be controlled in its position andit direction on the basis of a detecting signal from the sensor forsetting the container A to the punching device so as to compile with anon-line automatic production system.

[0177] Though the air suction hole 114 is punched in the neck 104 of thecontainer A by the punching device as mentioned in the first embodiment,the air suction hole 114 may be formed by any other hole-forming devicethan the punching device of the first embodiment or welding means.

[0178] The good result was obtained when the container A of thisembodiment was made in such a manner that the outer layer 111 was madeof polyethylene, the inner layer 112 was made of nylon, and the outerlayer 111 and the inner layer 112 were bonded with ADMER (adhesivepolyolefin) (trade mark, by Mitsui Sekyu-Kagaku Kogyo Kabushikikaisha)to form the bonded area.

[0179] The good result was also obtained when the container A was madein such a manner that the inner layer 112 was made by laminating ADMERon a nylon layer to decrease the water vapor permeability of the innerlayer 112.

[0180] [Third Embodiment]

[0181]FIG. 6 is a front view of a separable laminated container Aaccording to a third embodiment wherein parts being broken away and FIG.7 is a longitudinal sectional view of the same, as seen from the side.

[0182] The separable laminated container A is made up of an outer layer201 and an inner layer 202 and comprises a drum portion 203, a neck 204,and a bottom 205.

[0183] The outer layer 201 is made of high-density polyethylene to keepthe profile of the container, and the inner layer 202 is an inner bagmade of nylon which is separable from the outer layer and deformable.The outer layer 201 and the inner layer 202 of the container A are madeby blow molding of a laminated parison which is formed by co-extrusion.

[0184] In this embodiment, the nylon used in the inner layer 202 iscopolymer of nylon 6 having flexural modules of 650 kg/cm², providingexcellent flexibility.

[0185] Besides the nylon 6, any other nylon or any other synthetic resinmaterial may be employed for the inner layer 202. However, when theinner layer 202 is made of nylon 12 having flexural modules of 12,000kg/cm², the pre-separation should be made throughout the laminated face.This occurs the separation of the layers at the bottom 205 of thecontainer A.

[0186] Therefore, synthetic resin having flexural modules of equal to ormore than 10,000 kg/cm², that is, higher elasticity results a problem ofdifficulty of pre-separation and a problem of separation in the bottom.Therefore, it is preferable that the synthetic resin of the inner layer202 has flexural modules of less than 10,000 kg/cm².

[0187] The outer layer 201 and the inner layer 202 are partly bonded inthe longitudinal direction by a bonded area 206. The bonded area 206 isprovided if necessary and is formed at the same time as the laminatedparison by co-extrusion of the materials of the outer layer and theinner layer.

[0188] In case of providing the bonded area 206, the bonded area 206prevents the deformation of the inner layer 202 in the verticaldirection and allows the reduction and shrinkage in the radial directionduring the deformation of the inner layer 202 so as to easily pour outthe liquid content.

[0189] The bottom 205 of the container A has a projection 207 which isprovided with a plurality of sunk portions 208 formed by pinch-offs ofthe mold during blow molding.

[0190] By providing such a projection 207 having the-sunk portions 208,the bottom sealing portion can be strongly bonded even when the innerlayer 202 is made of resin such as nylon providing weak bond strength,thereby preventing the separation between the layers and the cracking ofthe bottom.

[0191] The neck 204 is provided with an engaging portion 209 formed atan upper end of inner layer 202 by an air blowing member during the blowmolding, thereby preventing the dip of the inner layer 202.

[0192] The neck 204 is provided with an air suction hole 210 punched inthe outer layer 201. The air suction hole 210 is a hole for introducingthe atmospheric air into a space between the inner layer 202 and theouter layer 201 in order to smoothly achieve the separation of the innerlayer 202 with keeping the profile of the container A to completely pourout the liquid content.

[0193] The air suction hole 210 is punched by using the punching deviceof the aforementioned first embodiment, that is, by setting a receivingface 212 of the receiving member 213 inside the neck 204 of thecontainer A, driving a punch 211 into the outer layer 201 from theoutside, and punching the outer layer 201 with the tubulous blade at theend of the punch 211 leaving the thickness of the inner layer 202behind.

[0194] In the container A, the inner layer 202 is previously separatedfrom the outer layer 201 before filling the liquid content, that is, thepre-separation is made.

[0195] With reference to FIG. 8 through FIG. 13, a pre-separation deviceC used in the pre-separation.

[0196] The pre-separation device C comprises a first air supply member220 for introducing pre-separating air through the air suction hole 210and a second air supply member 230 for pressing the container A at apredetermined position and introducing air into the container A throughthe neck 204.

[0197] The first air supply member 220 has a cylindrical body 221 whichis provided with a through hole 222 inside thereof, a nozzle 223 at thefront end of the cylindrical body 221, and a mounting portion 224 at therear end of the cylindrical body 221, wherein the mounting portion 224is provided with an internal thread 225 into which an air supply pipe isscrewed.

[0198] As shown in FIG. 10 and FIG. 11, the nozzle 223 has an opening222 a at the front end thereof and an opening 222 b formed in the endface for communicating the through hole 222 and the side of the nozzle223.

[0199] The cylindrical body 221 is provided with a cylindrical portion226 at the rear end of the cylindrical body 221. The cylindrical portion226 holds an engaging end 227 a at an end of a piston rod 227 of acylinder C₂ so as to communicate the first air supply member 220 and thecylinder C₂. In the cylindrical portion 226, a spring 228 is disposedbetween the cylindrical body 221 and the engaging end 227 a and acts asan absorber when the nozzle 223 is inserted into the air suction hole210.

[0200] The second air supply member 230 has a cylindrical block 231provided with a through hole 232 wherein the through hole 232 is bent insuch a manner as to have a horizontal portion and a vertical portion.

[0201] The block 231 has an engaging portion 233 formed at the lower endthereof which engages the neck 204 of the container A and presses theupper end of the container A so as to prevent the leakage of air. Anopening 232 a of the through hole 232 is formed in the center of theengaging portion 233.

[0202] The block 231 has a mounting portion 234 at the side thereof, themounting portion 234 being provided with an internal thread 235 intowhich an air supply pipe is screwed.

[0203] The block 231 is provided with a cylindrical portion 236 on theupper face thereof. The cylindrical portion 236 holds the engaging end237 a at the end of the piston rod 237 of the cylinder C₁ and connectsthe second air supply member 230 and the cylinder C₁. In the cylindricalportion 236, a spring 238 is disposed between the block 231 and theengaging end 237 a and presses the engaging portion 233 of the block 231to the neck 204 of the container A with a constant biasing force at thelower position of the piston rod 237, as well as acting as an absorber.In FIG. 8, FIG. 9, and FIG. 12, X, Y stand for the air supplyingdirections.

[0204] With reference to FIG. 12, the description will now be made asregard for an air supply system.

[0205] The cylinder C₁ for reciprocating the second air supply member230 up and down comprises a cylinder member and a piston P₁. The end ofthe piston rod 237 extending from the piston P1 is connected to thesecond air supply member 230 through the spring 238. The cylinder memberof the cylinder C₁ is provided with limit switches LS₁, LS₂ fordetecting the lower position and the upper position of the piston P₁.

[0206] The cylinder C₁ is connected to an isopiestic air tank(pressurized air supplier) 240 through a 4-port solenoid valve V₄ foroperation. The air tank 240 supplies air to either one of two inlets ofthe cylinder C₁ corresponding to ON/OFF of the solenoid valve V₄.

[0207] The cylinder C₂ for horizontally reciprocating the first airsupply member 220 comprises a cylinder member and a piston P₂. The endof the piston rod 227 extending from the piston P₂ is connected to thefirst air supply member 220 through the spring 228. The cylinder memberof the cylinder C₂ is provided with limit switches LS₃, LS₄ fordetecting the forward position and the backward position of the pistonP₂.

[0208] The cylinder C₂ is connected to the air tank 240 through 4-portsolenoid valve V₅ for operation. The air tank 240 supplies air to eitherone of two inlets of the cylinder C₂ corresponding to ON/OFF of thesolenoid valve V₅.

[0209] The first air supply member 220 is connected to the isopiesticair tank 240 through a pressure reducing valve 242, 2-port solenoidvalve V₁, a volume controller 250, and 3-port solenoid valve V₂.

[0210] When the solenoid valve V₁ is turned on, air depressurized to apredetermined pressure by the pressure reducing valve 242 is introducedfrom the air tank 240 to the volume controller 250. When the solenoidvalve V₁ is turned off and the solenoid valve V₂ is turned on, the airintroduced into the volume controller 250 is supplied to the first airsupply member 220.

[0211] The second air supply member 230 is connected to the air tank 240through a pressure reducing valve 243 and the 3-port solenoid valve V₃.

[0212] When the solenoid valve V₃ is turned on, air depressurized to apredetermined pressure by the pressure reducing valve 243 is introducedfrom the air tank 240 to the second air supply member 230.

[0213] The volume controller 250 comprises, as shown in FIG. 13, acylinder 251, a lid 252 of the cylinder 251, a plate-like flow settingmember 253, a ring-like sealing member 254 fixed to the flow settingmember 253, a positioning screw 255 screwed to an internal thread formedin the lid 252 and having an end connected to the flow setting member253, a knob-mounting end 256, and a lock nut 257. There is a pressurizedair storage 258 formed between a bottom wall of the cylinder 251 and theflow setting member 253.

[0214] As mentioned above, the air in the predetermined pressure isintroduced into the pressurized air storage 258 of the volume controller250 and a pipe line corresponding to ON/OFF of the solenoid valves V₁,V₂ and then introduced, as pre-separating air, between the outer layer201 and the inner layer 202 of the container A through the first airsupply member 220.

[0215] Though the volume of the pre-separating air depends on the volumeof the container A, the pre-separating air between 1 cc and 3 cc may beenough. Therefore, a small volume controller may be enough as the volumecontroller 250.

[0216] The volume of air is controlled by turning the knob-mounting end256 of the positioning screw 255 to control the position of the flowsetting member 253. Since a separated area 215 made by thepre-separation as shown in FIG. 9 is disposed in a small range betweenthe neck 204 and the shoulder of the container A, it is not necessary tocontrol the size of the separated area 215 depending on the volume ofthe container A. Once the separated area 215 is set to a predeterminedsize, it is not necessary to change the size even with containers A ofsomewhat different volumes.

[0217] Hereinafter, the pre-separation device C will be described.

[0218] The pre-separation device C is provided with an electriccontroller (not shown) as control means for controlling the opening andclosing of the respective solenoid valves V₁ through V₅. The controllerincludes two timers T₁, T₂ inside thereof and inputs a positional signalS₁ for detecting that the container A carried by a conveyer is held in apredetermined position and outputs an operational signal S₂ forcommanding to carry out the container A when the pre-separation iscompleted.

[0219] With reference to the timing chart of FIG. 14, the operation andthe pre-separation method of the pre-separation device C will bedescribed.

[0220] As a power source is turned on, the solenoid valve V₁ is alsoturned on so that the depressurized air is introduced into the volumecontroller 250 so that a fixed volume of air at a fixed pressure isstored.

[0221] As the positioning signal S₁ is then inputted, the solenoid valveV₁ is turned off, the solenoid valve V₄ is turned on, the piston P₁ ofthe cylinder C₁ moves down to the stroke end where the second air supplymember 230 engages and presses the neck 204 of the container A and thelimit switch LS₁ is turned on.

[0222] The turning-on of the limit switch LS₁ turns on the solenoidvalve V₅ so as to move the piston P₂ of the cylinder C₂ forward to thestroke end where the nozzle 223 of the first air supply member 220 isinserted into the air suction hole 210 of the neck 204 so that the innerlayer 202 is pressed by the distal end of the nozzle 223 and thusseparated from the outer layer 1 and the limit switch LS₃ is turned on.

[0223] The turning-on of the limit switch LS₃ turns on the solenoidvalve V₂ and the timer T₁ so that the air stored in the volumecontroller 250 is introduced between the outer layer 201 and the innerlayer 202 through the openings 222 a, 222 b of the nozzle 223 of thefirst air supply member 220 so as to separate a part of the inner layer202 to form the separated area 215. At this point, the distal end of thenozzle 223 moves forward according to the separation of the inner layer202 around the air suction hole 210 in such a manner that the opening222 b on its side is completely communicated with the separated area 215as shown in FIG. 9.

[0224] As the timer T₁ times out, the solenoid valve V₂ is turned offand the solenoid valve V3 and the timer T₂ are turned on so that the airat the fixed pressure is blown into the container A from the second airsupply member 230, the air previously introduced into the separated area215 is discharged from the opening 222 b on the side of the nozzle 223through the first air supply member 220, and the end of the nozzle 223is eventually moved backward to the outer layer 201 to completely returnthe inner layer 202 to the original state.

[0225] As the timer T₂ times out, the solenoid valve V₃ and the solenoidvalve V₅ are turned off so as to stop the blowing of the air by thesecond air supply member 230, move the piston P₂ of the cylinder C₂backward and move the first air supply member 220 backward.

[0226] When the piston P₂ of the cylinder C₂ is moved backward to thestroke end, the limit switch LS₄ is turned on and the solenoid valve V₄is thus turned off so as to move the piston P₁ of the cylinder C₁ upwardand move the second air supply member 230 upward.

[0227] When the piston P₁ reaches the upper position of the stroke end,the limit switch LS₂ is turned on so as to turn on the solenoid valve V₁and output the operational signal S₂ to carry out the container A fromthe position for the pre-separation.

[0228] As stated above, the container A with the air suction hole 210 isheld in the position for the pre-separation, after that, thepre-separating air is introduced between the outer layer 201 and theinner layer 202 through the air suction hole 210 by the first air supplymember 220, and then the air is blown into the container A through theneck 204 by the second air supply member 220 so as to discharge thepre-separating air previously introduced to return the inner layer 202to th original state. In this manner, the pre-separation is finished.

[0229] In the separable laminated container A of this embodiment, sincethe synthetic resin having flexural modules of less than 10,000 kg/cm²is employed as the material of the inner layer 202, the inner layer 202separated from the outer layer 201 smoothly shrinks according to thedecrease of the liquid content when the separable laminated container Ais in use.

[0230] In addition, by previously separating only a part of the innerlayer 202 around the air suction hole 10 from the outer layer 201, theair is smoothly introduced between the outer layer 201 and the innerlayer 202 even in the initial stage of pouring out the liquid contentwhen the separable container is in use, thereby facilitating theseparation of the inner layer 202.

[0231] Since only a part of the inner layer 202 is separated in thepre-separation, a small amount of pre-separating air is enough. Inaddition, it is not necessary to control the volume of the air even withseparable laminated containers A of somewhat different volumes so thatthe operation is easy.

[0232] Though the air suction hole 210 is formed in the neck 204 in theseparable laminated container A of this embodiment, the air suction hole210 may be formed in the drum portion 203. Though the air suction hole210 is punched by the punching means, the air suction hole 210 may bepunched by welding means.

[0233] [Fourth Embodiment]

[0234]FIG. 15 is a front view of showing a separable laminated containerA according to a fourth embodiment wherein parts being broken away, FIG.16 is a plan view of the same, and FIG. 17 is a side view of the same.

[0235] The separable laminated container A is made up of an outer layer301 and an inner layer 302 and comprises a drum portion 303, a shoulder304, a neck 305, and a bottom 313.

[0236] The outer layer 301 is made of high-density polyethylene to keepthe profile of the container A.

[0237] The inner layer 302 is an inner bag which is separable from theouter layer and deformable and is made of flexible resin such as nylonor EVOH (ethylene-acetic acid vinyl copolymer emulsion).

[0238] It should be understood that the materials of the outer layer 301and the inner layer 302 are not limited to the resin of this embodimentso that the materials may be any resin having the aforementionedcharacteristics.

[0239] The outer layer 301 and the inner layer 302 of the container Aare made by blow molding of a laminated parison which is formed byco-extrusion.

[0240] The neck 305 is provided with an air suction hole 306 punched inthe outer layer 301. The air suction hole 306 is a hole for introducingthe atmospheric air into a space between the outer layer 301 and theinner layer 302 in order to smoothly achieve the separation of the innerlayer 302 with keeping the profile of the container A to completely pourout the liquid content. The air suction hole 306 may be punched by usingthe punching device of the aforementioned first embodiment.

[0241] The neck 305 is provided with an engaging portion 307 formed atan upper end of inner layer 202 by a mandrel of an air blowing deviceduring the blow molding, thereby preventing the dip of the inner layer302. It should be noted that the engaging portion 307 is not necessarywhen the outer layer 301 and the inner layer 302 are partly bonded eachother.

[0242] The inner layer 302 has an expanded portion 309 separated fromthe outer layer 301 and projecting inwardly which is formed close to theair suction hole 306 by air blown for a pre-separation so that, next tothe extended portion 309, there is a space 308 formed between the outerlayer 301 and the inner layer 302

[0243] As for the pre-separation, the pre-separation is made beforefilling the liquid content into the container A.

[0244] The pre-separation is made by using a pre-separation device 310as shown in FIG. 18. As shown in FIG. 19, the pre-separation device 310is provided with a through hole 311 inside thereof and a nozzle 312 atth front end thereof.

[0245] The nozzle 312 is provided with an opening 311 a at the front endthereof and an opening 311 b communicating with the side of the nozzle312 wherein air is blown downward from the opening 311 b.

[0246] In the pre-separation, the nozzle 312 of the pre-separationdevice 310 is inserted into the air suction hole 306 of the neck 305 anda fixed amount of pre-separating air is blown so that the separation ofthe inner layer 302 starts from a portion around the neck 305 and thentravels to the shoulder 304 and an upper portion of the drum portion 303until a portion of the inner layer 302 surrounded by the line 302 b asshown in FIG. 16 and FIG. 17 is separated from the outer layer 301,thereby forming the extended portion 309.

[0247] In the pre-separation, the extended portion 309 is formed byblowing such an amount of air as to extend the separated inner layer 302a at least to the inside of the neck 305.

[0248] After the inner layer is separated from the outer layer, whilethe separated inner layer is returned to the original state to come incontact with the outer layer by blowing air into the container A throughthe neck to discharge the pre-separating air in the third embodimentmentioned above, the extended portion 309 of the separated inner layer302 a is held in this state in this fourth embodiment.

[0249] After the pre-separation, it is checked whether thepre-separation was securely made or not by observing the extendedportion 309 from an upper position over the neck 305 with a telecameraor the like. Then, the container A is carried out.

[0250] The description will now be made as regard to the filling of theliquid content into the container A.

[0251] The upper space in the container A filled with the liquid contentis generally dependent on the volume of the container A and the amountof the filled liquid content. When a fixed amount of liquid content isfilled into the container A having such an extended portion 309 as thisembodiment, however, the upper space after filling is reduced accordingto the size of the extended portion 309 so that the level La of theliquid content at this point is risen by the volume excluded by theextended portion 309 as compared with the level Lb in case of noextended portion 309 as shown in FIG. 18.

[0252] Since the hydraulic pressure at the extended portion 309 is quitesmall and the inner layer 302 has somewhat form retentivity even whenthe inner layer is flexible, little amount of the pre-separating air isdischarged even after filling the liquid content so that the form of theextended portion 309 is substantially kept even after filling the liquidcontent.

[0253] When a cap is fitted to the neck 305, the level La is keptconstant because no air is entered into the container A so that nopre-separating air is discharged.

[0254] According to this embodiment, the upper space in the container Aand the level of the liquid content after filling the liquid content canbe controlled by the size of the extended portion 309 or the volume ofthe space 308. Therefore, the level of the liquid content can be easilyrisen to near the neck 305 even with the same amount of liquid contentby controlling the volume of the pre-separating air.

[0255] The same is true for the container A with large volume.Conventionally, in case of the container A with large volume, the levelof the liquid content is lowered below the neck 305 or to the lowerportion of the shoulder and near the upper end of the drum portion 303so as to make the upper space after filling the liquid content wider sothat the water face of the liquid content waves, thereby bubbling theliquid content during the container is transported. In case of thecontainer A with the extended portion 309 of this embodiment, however,the level of the liquid content can be risen to the neck 305 by settingthe extended portion 309 to a predetermined size, thereby decreasing thewaves of the water face of the liquid content and the swing of theliquid content during the container A is transported.

[0256] In addition, as the upper space after filling the liquid contentis small, this gives a consumer the impression of fulfillment when theconsumer has the container A in his/her hand.

[0257] Further, the step for blowing air into the container A in orderto discharge the pre-separating air is not necessary in thepre-separation process, thereby facilitating the manufacturing process.

[0258] Furthermore, the inner layer 302 and the outer layer 301 are notconnected by blowing the air into the container A, thereby improving theseparability of the inner layer 302 when the container A is in use.

[0259] Moreover, the state of the pre-separation can be inspected justby observing the inside of the container A from the upper side of theneck 305 of the container A.

[0260] [Fifth Embodiment]

[0261]FIG. 20 is a front view showing a container with pump according toa fifth embodiment wherein parts being broken away. The container withpump comprises a container body (separable laminated container) D madeup of an outer layer 401 and an inner layer 402, and a pump E fitted tothe container body D.

[0262] First, the container body D will be described. As shown in FIG.23 and FIG. 24, the container body D comprises a drum portion 403, ashoulder 404, a neck 405, and a bottom 413.

[0263] The outer layer 401 is made of high-density polyethylene to keepthe profile of the container body D.

[0264] The inner layer 402 is an inner bag which is separable from theouter layer 401 and deformable and is made of flexible resin such asnylon or EVOH (ethylene-acetic acid vinyl copolymer emulsion).

[0265] It should be understood that the materials of the outer layer 401and the inner layer 402 are not limited to the resin of this embodimentso that the materials may be any resin having the aforementionedcharacteristics.

[0266] The outer layer 401 and the inner layer 402 of the container bodyD are made by blow molding of a laminated parison which is formed byco-extrusion.

[0267] The neck 405 is provided with an air suction hole 406 punched inthe outer layer 401. The air suction hole 406 is a hole for introducingthe atmospheric air into a space between the outer layer 401 and theinner layer 402 in order to smoothly achieve the separation of the innerlayer 402 with keeping the profile of the container body D to completelypour out the liquid content. The air suction hole 406 may be punched byusing the punching device of the aforementioned first embodiment.

[0268] The neck 405 is provided with an engaging portion 407 formed atan upper end of inner layer 402 by a mandrel of an air blowing deviceduring the blow molding, thereby preventing the dip of the inner layer402. It should be noted that the engaging portion 407 is not necessarywhen the outer layer 401 and the inner layer 402 are partly bonded eachother.

[0269] The inner layer 402 has an expanded portion 409 separated fromthe outer layer 401 and projecting inwardly which is formed close to theair suction hole 406 by air blown for a pre-separation so that, next tothe extended portion 409, there is a space 408 formed between the outerlayer 401 and the inner layer 402 As for the pre-separation, thepre-separation is made before filling the liquid content into thecontainer body D.

[0270] The pre-separation is made by using a pre-separation device 410as shown in FIG. 21. As shown in FIG. 22, the pre-separation device 410is provided with a through hole 411 inside thereof and a nozzle 412 atthe front end thereof.

[0271] The nozzle 412 is provided with an opening 411 a at the front endthereof and an opening 411 b communicating with the side of the nozzle412 wherein air is blown downward from the opening 411 b.

[0272] In the pre-separation, the nozzle 412 of the pre-separationdevice 410 is inserted into the air suction hole 406 of the neck 405 anda fixed amount of pre-separating air is blown so that the separation ofthe inner layer 402 starts from a portion around the neck 405 and thentravels to the shoulder 404 and an upper portion of the drum portion 403until a portion of the inner layer 402 surrounded by the line 402 b asshown in FIG. 23 and FIG. 24 is separated from the outer layer 401,thereby forming the extended portion 409.

[0273] The pre-separation device 410 is connected to an air supplyingdevice with a volume controller which facilitates the control of theamount of the supplied pre-separating air in a fixed range.

[0274] In this embodiment, the neck 405 is provided with the air suctionhole 406 punched in the outer layer 401 so that the air suction hole 406is covered by a cap 420 of the pump E when the pump E is fitted to thecontainer body D. However, the air suction hole 406 may be formed in anupper end of the shoulder 404, or any suitable portion of the shoulder404 or drum portion 403.

[0275] After the inner layer is separated from the outer layer, whilethe separated inner layer is returned to the original state to come incontact with the outer layer by blowing air into the container body Dthrough the neck to discharge the pre-separating air in the thirdembodiment mentioned above, the extended portion 409 of the separatedinner layer 402 a is held in this state in this fifth embodiment.

[0276] When a fixed amount of liquid content is filled into thecontainer body D, the upper space after filling is reduced according tothe size of the extended portion 409 so that the level La of the liquidcontent at this point is risen by the volume excluded by the extendedportion 409 as compared with the level Lb in case of no extended portion409 as shown in FIG. 21.

[0277] Since the hydraulic pressure at the extended portion 409 is quitesmall and the inner layer 402 has somewhat form-retentivity even whenthe inner layer is flexible, little amount of the pre-separating air isdischarged even after filling the liquid content so that the form of theextended portion 409 is substantially kept even after filling the liquidcontent.

[0278] The pump E is fitted to the container body D filled with theliquid content as mentioned above. The description will be first made asregard to the pump E with reference of FIG. 20 and FIG. 26.

[0279] The pump E comprises the cap 420, a cylinder 421 provided with apiston and a valve mechanism inside thereof, and an operational member422 for the piston.

[0280] The cylinder 421 is provided with a lid 423, having a throughhole into which a piston rod is inserted, at the upper end thereof and amounting flange 424 around an upper portion thereof.

[0281] The cylinder 421 is provided with a flange-like seal 425 extendedoutwardly at the lower end thereof. The seal 425 comes in contact withthe inner circumference 405 a of the neck 405 of the container body Dtightly during fitting the pump E in order to keep the airtightness withthe neck 405.

[0282] The cylinder 421 is provided with a valve seat cylinder 426extending from a lower portion of the cylinder 421 and a suction pipe427 extending downward from the valve seat cylinder 426. The operationalmember 422 is provided with a discharge pipe 428 extending therefrom fordischarging the liquid content.

[0283] Since the internal structure of the pump E is well known in theart, the detailed description with reference to the drawings will beomitted. The piston reciprocates up and down by pushing operation of theoperational member 422 and the restoring force of a compressed springdisposed in the cylinder 421 so as to discharge a fixed amount of liquidcontent according to the operation of the operational member 422.

[0284] The piston is held at the lowest position and a valve memberdisposed in the bottom of the cylinder 421 is fixed to the closedposition by rotating the operational member 422 at the lower position toengage the lid 423, thereby preventing the flow of the liquid contentbetween the suction pipe 427 and cylinder 421 for fitting the pump E orwhen the container is not in use.

[0285] The pump E is fitted in the same manner as that of a commoncontainer with pump. The cap 420 is fitted to the neck 405 in such amanner as to dispose the mounting flange 424 of the cylinder 421 and apacking 430 between the cap 420 and the neck 405.

[0286] Hereinafter, the function of the seal 425 when the pump E ismounted and the level of the liquid content will be described withreference to FIG. 25 and FIG. 26.

[0287]FIG. 25 shows a state where the suction pipe 427 and the valveseat cylinder 426 are inserted into the container body D and the seal425 of the cylinder 421 is in contact with the upper inner edge 405 b ofthe neck 405 to compress the upper edge 405 b so that the container bodyD is sealed. FIG. 26 shows a state where the installation of the pump Eis completed.

[0288] In the sealed state as shown in FIG. 25, the upper space in thecontainer body D is reduced by the volume of pumping member (the valveseat cylinder 426 and the suction pipe 427) inserted into the containerbody D as compared with the same before the insertion of the pump andthe level L1 is slightly higher than the level La (see FIG. 21) beforethe insertion by the volume of the suction pipe 427.

[0289] As the pump E is pushed downward from the state as shown in FIG.25, the seal 425 moves downward along the inner circumference 405 a ofthe neck 405 so as to discharge the pre-separating air in the space 408and make the level lower until reaching a position corresponding to theair suction hole 406.

[0290] Once the seal 425 reaches the position corresponding to the airsuction hole 406, the air suction hole 406 is stopped up by the innerlayer 402 so as to stop the discharge of the pre-separating air.

[0291] After that, the pre-separating air does not discharged and theair in the container body D is just compressed until the seal 425reaches a lower inner edge 405 c of the neck 405.

[0292] As the seal 425 moves downward apart from the lower edge 405 c,the airtightness of the container body D is released and the compressedair in the container body D is discharged through a space between thecylinder 421 and the neck 405.

[0293] When the air suction hole 406 is formed in any other place thanthe neck 405, the pre-separating air in the space 8 is dischargedaccording to the descent of the pump E until the seal 425 reaches thelower edge 405 c. As the seal 425 moves downward apart from the loweredge 405 c, the airtightness of the container body D is released and thedischarge of the pre-separating air is stopped.

[0294] As the pump E is further pushed downward after the seal 425reaches the lower edge 405 c of the neck 405, the level of the liquidcontent is risen by the volume of the cylinder 421 submerged into theliquid content and becomes the level L2 when the cap 420 is fitted tothe neck 405.

[0295] Since the container body D is tightly sealed after theinstallation of the pump, the pre-separating air is no longer dischargedand the upper space in the container body D and the level of the liquidcontent are kept constant.

[0296] The description will now be made as regard to the relationbetween the upper space in the container body D and the volume ofpre-separating air.

[0297] Assuming that Qa is the initial volume of the pre-separating airfilled into the space 408 during the pre-separation before theinstallation of the pump,

[0298] Qb is the volume of the air discharged from the space 408 duringthe installation of the pump, and

[0299] Qc is the volume of residual air remaining in the space 408 afterthe installation of the pump, the following expression holds for thevolume of the pre-separating air:

Qa=Qb+Qc

[0300] The initial volume Qa can be controlled by the volume controllerof the air supplying device connected to the pre-separation device 410.

[0301] The discharged volume Qb is found form the configuration and thedimensions of the container body D.

[0302] The air in the container body D, which is sealed during theinstallation of the pump, is compressed according to the elevation ofthe cylinder 421. When the air suction hole 406 is not stopped up, theair in the container body D has a pressure equal to the atmosphericpressure because of the deformation of the inner layer 402. Therefore,the compression of the air in this case is negligible.

[0303] The discharged volume Qb is given by the following expression:

Qb=πr²h

[0304] where r is the radius of the inner circumference 405 a of theneck 405, and

[0305] h is the height from the upper edge 405 b of the neck 405 to theair suction hole 406.

[0306] When the air suction hole 406 is formed in any other place thanthe neck 405, the discharged volume Qb is given by the followingexpression:

Qb=πr²ha

[0307] where r is the radius of the inner circumference 405 a of theneck 405, and

[0308] ha is the height from the upper edge 405 b to the lower edge 405c of the neck 405.

[0309] At this point, the radius r, the height h, ha are fixed valuesdefined from the design of the container body D so that the dischargeamount Qb is a constant value.

[0310] The residual volume Qc of the residual air in the space 408 isfound from a difference between the initial volume Qa and the dischargedvolume Qb(Qc=Qa−Qb). Since the Qb is a constant value, the residualvolume Qc can be freely set by controlling the initial volume Qa.

[0311] The description will now be made as regard to the upper space inthe container body D after the installation of the pump.

[0312] Though it is possible to quantitatively analyze the variation inthe upper space and the level of the liquid content, the analyses arecomplex and the detailed analyses are not necessary. Therefore, theaction and effect of this embodiment with regard to the upper spaceafter the installation of the pump will be apparent from comparisonbetween the container of this embodiment and the conventional container.

[0313] The volume of the upper space after the installation of the pumpis found by subtracting the volume of the filled liquid content and thevolume of the pumping member (the cylinder 421, the valve seat cylinder426, and the suction pipe 427) which are inserted into the containerbody D from the volume of the container body D.

[0314] Letting the volume of the container body without the extendedportion 409 or the container body in which the inner layer is returnedto the original state is Vo, the volume Vo is a constant value becausethe volume of the container body and the volume of the liquid contentare known and the volume of the pumping member is defined by theconfigurations of the dimensions thereof.

[0315] Letting the volume of the upper space in the container body Dwith the extended portion 409 is V, the volume V of the upper space ofthis embodiment is reduced by the residual volume Qc of thepre-separating air in the space 408 because of the extended portion 409because the volume of the liquid content and the volume of the pumpingmember inserted into the container body D are the same as those of theconventional container.

[0316] Therefore, the volume V of the upper space of this embodiment isfound by the following expression: $\begin{matrix}{V = {{Vo} - {Qc}}} \\{= {{Vo} - {\left( {{Qa} - {Qb}} \right).}}}\end{matrix}$

[0317] In the above expression, since Vo is a constant value and Qb isalso a constant value, it is found that the volume V of the upper spaceis variable corresponding to the initial value Qa.

[0318] When the volume V of the upper space becomes negative, it meansthat the content overflows from the neck 405. Therefore, it should beunderstood that Qa should be set in such a manner as to holding V>0.

[0319] The air is just compressed from a point in time when the volumeof the air discharged from the space 408 becomes equal to the initialvolume Qa while the cylinder 421 descends, to a point in time when theseal 425 reaches the lower edge 405 c of the inner surface of the neck405. Therefore, to set Qa<Qb, the volume of the upper space duringinserting the pump should be larger than a value found by subtractingthe initial volume Qa from the volume of the neck because the liquidcontent is incompressible.

[0320] The action and effect of this embodiment will be describedhereinafter.

[0321] Since, as described above, the initial volume Qa is controllableby the volume controller of the air supplying device, the volume of theupper space after the pump E is installed and the level of the liquidcontent can be easily controlled by controlling Qa.

[0322] When the initial volume Qa is set to be equal to the dischargedvolume Qb, the pre-separating air within the space 408 is completelydischarged anid the separated portion 402 a of the inner layer 402 isreturned to the original state so as to bring the separated portion 402aof the inner layer 402 in contact with the outer layer 1.

[0323] Therefore, in this case, the inner layer 402 can be returned tothe original state during the installation of the pump without blowingair into the container body D through the neck 405 in the pre-separationprocess after the pre-separating air is introduced between the outerlayer 401 and the inner layer 402.

[0324] As the initial volume Qa increases, the residual volume Qc of theair remaining in the space 408 increases, and the upper space reducesand the level of the liquid content rises as compared with a case wherethe separated portion 402 a of the inner layer 402 is returned in theoriginal state.

[0325] By setting the initial volume Qa into a predetermined value, thelevel can be positioned in the neck 405 when the volume V of the upperspace is set to be equal to or less than the value found by subtractingthe volume of the cylinder 421 of the pump E inserted in the neck 405from the volume of the neck 405.

[0326] Therefore, even with the container with pump of which the volumeof the container body D is large so that the upper space is large andthe level of the liquid content is lowered to the lower portion of theshoulder 404, the level of the liquid content can be easily risen to theneck 405 after the installation of the pump, thereby decreasing thewaves of the water face of the liquid content and the swing of theliquid content during the container body D is transported and thuspreventing the bubbling and the generation of gases.

[0327] [Sixth Embodiment]

[0328] With reference to FIG. 27 through FIG. 29, a container with pumpaccording to a sixth embodiment will be described.

[0329] The difference between the container with pump of the sixthembodiment and that of the fifth embodiment is that a seal is formed inan inner lid F fitted to the neck 405 of the container body D instead ofproviding the seal 425 formed in the lower end of the periphery of thcylinder 421 of the pump E.

[0330] The inner lid F is made of synthetic resin and comprises acylindrical portion 432 provided with a flange 431 at the upper edgethereof and a ring-like seal 433 disposed on the lower end of thecylindrical portion 432 and projecting inward.

[0331] The seal 433 has a contact surface 434 around the innercircumference thereof which comes in contact with the outer surface ofthe cylinder 421 to compress the outer surface in such a manner as toseal the container body D during the installation of the pump.

[0332] The pump E is installed by fitting the inner lid F to the neck405 and then inserting the cylinder 421 of the pump E into the inner lidF.

[0333] As the lower end of the cylinder 421 is in contact with the seal433, the inside of the container body D is sealed. As the pump E isfurther pushed down, the pre-separating air within the space 408 isdischarged through the air suction hole 406 corresponding to the volumeof the cylinder 421 inserted through the seal 433.

[0334] Since the inside of the container body D is in the sealed state,the level of the liquid content is lowered corresponding to the descentof the pump E so that the level becomes L2 from L1. Once the cylinder421 reaches the level, the volume of the cylinder 421 submerged into theliquid content is replaced by the volume of air discharged from thespace 408 so that the level does not change.

[0335] The pump E is installed to the container body D by pushing downthe cylinder 421 to the lowest position and then fitting the cap 420 tothe neck 405.

[0336] Since the container body D is tightly sealed after theinstallation of the pump, the air within the space 408 is no longerdischarged and the upper space in the container body D and the level ofthe liquid content are kept constant.

[0337] The description will now be made as regard to the relationbetween the upper space in the container body D and the volume ofpre-separating air.

[0338] Assuming that Qa is the initial volume of the pre-separating airfilled into the space 408 during the pre-separation before theinstallation of the pump,

[0339] Qb is the volume of the air discharged from the space 408 duringthe installation of the pump,

[0340] Qc is the volume of residual air remaining in the space 408 afterthe installation of the pump,

[0341] Vo is the volume of the upper space in the container body D afterthe installation of the pump in case of the container body D without theextended portion 409,

[0342] V is the volume of the upper space in the container body D afterthe installation of the pump in case of the container body D with theextended portion 409 of this embodiment (the upper space in case of thesix embodiment indicates a space under the seal 433 of the inner lid F),

[0343] s is the length between the seal 433 and the lower end of thecylinder 421 when the pump E is fitted to the container body D, and

[0344] r_(c) is the radius of the cylinder 421, the following expressionholds for the volume of the discharged air:

Qb=πr_(c) ²s

[0345] when the compression of the air within the container body D isneglected.

[0346] The discharged volume Qb is a constant value because it is foundfrom the dimensions of the pumping member (the cylinder 421).

[0347] As well as the case of the fifth embodiment, the followingexpression holds with regard to the relation between the volumes V, Vo:$\begin{matrix}{V = {{Vo} - {Qc}}} \\{= {{Vo} - {\left( {{Qa} - {Qb}} \right).}}}\end{matrix}$

[0348] In the above expression, since Vo is a constant value and Qb isalso a constant value, it is found that the volume V of the upper spacein case of this embodiment having the extended portion 409 is variablecorresponding to the initial value Qa.

[0349] Therefore, the sixth embodiment has also the same effects as thefifth embodiment by controlling the initial value Qa.

[0350] In addition, since the inner lid F is fitted into the neck 405 inthe sixth embodiment, the upper space can be further reduced than thefifth embodiment.

[0351] As mentioned above, during pushing down the pump E for installingthe pump, while the level of the liquid content is lowered from thepoint where the lower end of the cylinder 421 comes in contact with thering-like seal 433 to the point where the cylinder 421 reaches thelevel, the level does not change after that.

[0352] When the liquid content is filled close to the seal 433 of theinner lid E, the level slightly rises by the insertion of the suctionpipe 427 and after that little variation in the level is caused. Thisexhibits an effect of predicting the level in filling the liquidcontent.

[0353] Since the air within the space 408 is discharged by installingthe pump E to the container body D, the step for blowing air into thecontainer A in order to discharge the pre-separating air is notnecessary in the pre-separation process, thereby facilitating themanufacturing process.

[0354] Moreover, the state of the pre-separation can be inspected justby observing the inside of the container body D from the upper side ofthe neck 305 of the container A.

[0355] In addition, as the upper space in the upper space is small sothat the liquid content does not splash when the consumer has thecontainer A in his/her hand, this gives a consumer the impression offulfillment, thereby improving the value as a commercial product.

[0356] [Seventh Embodiment]

[0357] With reference to FIG. 30 and FIG. 31, a container with pumpaccording to a seventh embodiment will be described.

[0358] In the container with pump of the sixth embodiment as mentionedabove, the level of the liquid content rises according to the descent ofthe cylinder 421 after Qa=Qb and the air within the container body D iscompressed when the initial volume Qa is set to be smaller than thedischarged volume Qb (Qa<Qb).

[0359] In the container with pump of the fifth embodiment, since thesealed state of the container body is released when the seal 425 of thecylinder 421 is lowered below the lower edge 405 c of the neck 405, thecompressed air is discharged into the atmosphere so that there is noproblem.

[0360] On the other hand, in case of the sixth embodiment, since theseal 434 of the inner lid F is in contact with the outer surface of thecylinder 421 to compress the outer surface and the sealed state is keptto the end, the air within the container body D is compressed so thatthere is a problem of rise in the inner pressure of the container bodyD.

[0361] To overcome this problem, it is needed, of cause, to control ofthe initial volume Qa not to make the upper space negative and,additionally, to provide means for allowing the release of thecompressed air.

[0362] The seventh embodiment is a container with pump provided withsuch a compressed air releasing means.

[0363] Conventionally, as shown in FIG. 32, there is a pump which isprovided with narrow grooves 421 a through which air flows formed in theouter surface of the cylinder 421 in order to completely pour out theliquid content. However, the upper ends of the grooves 421 a of theconventional container does not reach the seal 433 of the inner lid F.

[0364] In the container with pump of the seventh embodiment, as shown inFIG. 31, the cylinder 421 has narrow grooves 421 a formed in the outersurface the cylinder 421 between the lower edge thereof and at least toa position where the grooves reach the seal 433. The grooves constitutethe compressed air releasing means.

[0365] The contact surface 434 of the ring-like seal 433 of the innerlid F is compressing the outer surface of the grooves 421 a, therebyallowing the flow of air between the cylinder 421 and the seal 433 andpreventing the flow of the liquid content therebetween because of itsviscosity.

[0366] Therefore, when the air within the container body D is compressedafter Qa≦Qb, the compressed air is discharged through the grooves 421 a,thereby preventing the rise in the inner pressure of the container bodyD.

[0367] Though the compressed air releasing means is made up of thenarrow grooves 421 a formed in the outer surface of the cylinder 421 inthis embodiment, the compressed air releasing means may be made up ofthe roughed surface made by blasting the outer surface of the cylinder421.

[0368] [Eighth Embodiment]

[0369] With reference to FIG. 33, a container with pump according to aneighth embodiment will be described.

[0370] Though the compressed air releasing means is made up of thegrooves or the roughened surface formed in the outer surface of thecylinder 421 of the pump E in the seventh embodiment described above,the compressed air releasing means according to the eighth embodiment ismade up of narrow grooves or roughened surface 434 a formed in thecontact surface 434 of the inner lid F.

[0371] In this case, there is an advantage of using a conventionalcylinder 421 without any change.

[0372] [Ninth Embodiment]

[0373] With reference to FIG. 34 through FIG. 37, a container with pumpaccording to a ninth embodiment will be described.

[0374] The ninth embodiment is also the container with pump having ancompressed air releasing means in an inner lid F.

[0375] As shown in FIG. 36, the inner lid F used for the container withpump of the ninth embodiment comprises a flange 431, a cylindricalportion 432, and a ring-like flexible seal 435 projecting inward andupward from the lower edge of the cylindrical portion 432, wherein theseal 435 comes in contact with the outer surface of the pump E tightly.

[0376] The inner lid F is made of flexible synthetic resin. Therefore,when the inner pressure of the container body D rises, the seal 435 isdeformed and its end 435 a is extended to form a space between the seal435 and the cylinder 421 through which the compressed air and/or theliquid content are discharged.

[0377] Therefore, when the air within the container body D is compressedbecause the initial volume Qa is set to be smaller than the dischargedair Qb (Qa<Qb), the compressed air is discharged through the space.

[0378] In the ninth embodiment, since the flexible seal 435 projectsinward and upward, it is quite easy to completely fill the liquidcontent beneath the inner lid F as shown in FIG. 37 when the volume ofthe upper surface after filling the liquid content and before installingthe pump is set to be equal to the volume of the valve seat cylinder 426and the suction pipe 427 of the pump E. This is because, afterinstallation of the pump, the level of the liquid content rises to theseal 435 and after that the level does not change.

[0379] In this case, since the liquid content escapes through the space,there is no problem even when the level of the liquid content rises overthe seal 435 if it is a little amount.

[0380] It should be understood that the container with pump of any oneof the seventh embodiment, the eighth embodiment, and the ninthembodiment exhibits the same effects as the sixth embodiment when theinitial volume Qa is set to be greater than the discharged volume Qb(Qa≧Qb).

[0381] Though a pump generally used has been employed as the pump E inthe container with pump of any one of the fifth embodiment through theninth embodiment, the pump E of the present invention is not limited tothe pump of the embodiments and may be any pump which can suck up anddischarge the fixed amount of liquid content by the action of theoperational member, with the cylinder members thereof being insertedinto the container body D.

[0382] Industrial Applicability

[0383] The separable laminated container of the present invention allowsthe inner layer to be securely and easily separated from the outer layerand can be used as a container for accommodating various types of liquidsuch as face lotion, shampoo, and rinse, and is particularly suited fora container with pump.

1. A container with pump comprising: (a) a container body made up of aninner layer and an outer layer which are made of synthetic resin andseparably laminated on each other, wherein the outer layer has an airsuction hole formed therein and a portion of said inner layer adjacentto the air suction hole is partly separated from the outer layer; and(b) a pump comprising a cylinder inserted into the container bodythrough a neck of said container body and a cap whereby the pump ishermetically fitted to said neck, wherein the cylinder is provided witha flange-like seal around the outer periphery thereof, the flange-likeseal coming in contact with the inner surface of said neck tightly.
 2. Acontainer with pump comprising: (a) a container body made up of an innerlayer and an outer layer which are made of synthetic resin and separablylaminated on each other, wherein the outer layer has an air suction holeformed therein and a portion of said inner layer adjacent to the airsuction hole is partly separated from the outer layer; (b) a pumpcomprising a cylinder inserted into the container body through a neck ofsaid container body and a cap whereby the pump is hermetically fitted tosaid neck; and (c) an inner lid having a ring-like seal coming incontact with the outer surface of the cylinder of said pump tightly, andfitted in the neck of said container body.
 3. A container with pump asclaimed in claim 2, wherein said cylinder has a narrow groove or aroughened surface on the outer surface thereof extending from the loweredge thereof to a position above the seal of the inner lid afterinstallation of the pump.
 4. A container with pump as claimed in claim2, wherein said seal of said inner lid has a narrow groove or aroughened surface formed in a sealing surface thereof.
 5. A containerwith pump as claimed in claim 2, wherein said seal of said inner lidprotrudes inward and upward in such a manner as to elastically expandand contract in the radial direction.